What are the packaging options for high-voltage capacitors?

There are various packaging forms for high-voltage capacitors to meet the voltage, current, size, and reliability requirements of different application scenarios. The packaging system of high-voltage capacitors is systematically analyzed from three dimensions: general packaging types, high-voltage specific packaging, and brand specific packaging, combined with parameters such as size, material, and application scenarios
1、 Universal Packaging Types: Standardization and Wide Applicability
1. Radial Leaded Packaging
Structural features:
Cylindrical body with metal leads at both ends, with fixed lead spacing (e.g. 2.54mm, 5.08mm).
Typical packaging: RD series (such as RD10, RD15).
Advantages:
Low cost, suitable for large-scale production.
Easy to manually weld and convenient to repair.
Application scenarios:
Industrial power supply, consumer electronics (such as chargers, LED drivers).
Rated voltage: usually<500V, some high-voltage models can reach 1000V.
2. Axial Leaded Packaging
Structural features:
Cylindrical body, with leads extending axially from both ends and adjustable lead spacing.
Typical packaging: AX series (such as AX50, AX100).
Advantages:
High mechanical strength and excellent anti vibration performance.
Suitable for high-frequency circuits with low lead inductance.
Application scenarios:
Communication equipment, automotive electronics (such as ABS controllers).
Rated voltage: usually<1000V, some high-voltage models can reach 2000V.
3. Surface mount packaging (SMD)
Structural features:
Rectangular or cylindrical body, with metal pads at the bottom and no leads or short leads.
Typical packaging: 1206 (3.2mm × 1.6mm), 1812 (4.5mm × 3.2mm).
Advantages:
Small size, suitable for high-density PCB layout.
Automated mounting has high efficiency and good consistency.
Application scenarios:
Smartphones, TWS earphones, 5G base stations.
Rated voltage: usually<100V, some high-voltage models can reach 500V.
2、 High voltage specialized packaging: pressure resistance and heat dissipation optimization
1. Bull horn packaging (Snap in)
Structural features:
Cylindrical body with plastic buckle at the top, and quick connect terminals for the leads.
Typical packaging: SNAP series (such as SNAP-IN 35 × 50).
Advantages:
High voltage resistance (up to 600V), suitable for high current scenarios.
Excellent heat dissipation performance and long lifespan.
Application scenarios:
Industrial power sources, new energy vehicles (such as battery management systems).
Rated voltage: usually>450V, some models can reach 600V.
2. Screw Terminal
Structural features:
Cylindrical body with threaded holes at the top, connected by bolts for fixation.
Typical packaging: BOLT series (such as BOLT 50 × 100).
Advantages:
Extremely high voltage resistance (up to 2000V), suitable for high-voltage and high-power scenarios.
The mechanical connection is reliable and has strong anti vibration performance.
Application scenarios:
Power transmission, high-voltage direct current transmission (HVDC), welding machines.
Rated voltage: usually>1000V, some models can reach 2000V.
3. Metal Can Packaging
Structural features:
Cylindrical metal casing, with leads leading out from the bottom or side.
Typical packaging: MC series (such as MC 25 × 50).
Advantages:
High voltage resistance (up to 3000V), suitable for extreme environments.
Excellent shielding performance and strong resistance to electromagnetic interference (EMI).
Application scenarios:
Aerospace and military equipment (such as radar and missile guidance systems).
Rated voltage: usually>1500V, some models can reach 3000V.
3、 Brand Feature Packaging: Technological Differentiation and Scene Adaptation
1. Vishay (Vishay, USA)
Featured packaging:
High voltage ceramic capacitor: using multi-layer ceramic (MLCC) technology, with small packaging size (such as 0402, 0603), and a withstand voltage of up to 3000V.
Application scenarios:
5G communication module, high-speed digital circuit.
2. TDK (Japan TDK)
Featured packaging:
High voltage film capacitor: Made of metalized polypropylene film, with various packaging forms (such as axial leads and surface mount), with a withstand voltage of up to 6000V.
Application scenarios:
Industrial power supply and new energy generation.
3. Hongda Electronics (Hunan Hongda, China)
Featured packaging:
High voltage solid-state capacitor: using conductive polymer electrolyte, compact packaging size (such as 1210, 1812), with a withstand voltage of up to 2000V.
Application scenarios:
New energy vehicles, consumer electronics.
4、 Packaging selection logic: voltage, current, and spatial balance
High voltage scenario: Priority should be given to horn packaging, bolt packaging, or metal shell packaging, with a pressure resistance greater than 1000V.
High frequency requirements: Choose surface mount packaging or axial lead packaging with low lead inductance.
Space limited design: using surface mount packaging (such as 1206, 0805), with a small volume.
High current scenario: Choose horn packaging or bolt packaging for excellent heat dissipation performance.
Based on the above analysis, the packaging form of high-voltage capacitors needs to be comprehensively considered in combination with voltage level, current capacity, space limitations, and reliability requirements. With the advancement of materials science and manufacturing technology, the packaging of high-voltage capacitors will continue to develop towards miniaturization, high frequency, and high voltage resistance.